Seamless gel cushion

ABSTRACT

A gel cushion, and a method of manufacturing same, in accordance with the present invention generally includes the steps of cooling a mold to a selected temperature, disposing a porous stretchable fabric over the cooled mold, depositing a volume of gelable liquid within the mold such that the cooled mold enables pores of the fabric to fill with gel without penetration therethrough, applying a vacuum between the fabric and the mold, allowing the gel to set and solidify and removing the solidified gel having the fabric fixed thereto in order to obtain the gel cushion. Another embodiment of the invention includes the step of filling a second matching mold and bonding the two volumes of gelable liquid together in order to make a fabric enclosed gel cushion. Yet another embodiment of the invention includes the step of depositing air filled bags or balloons on the coated fabric prior to injecting the additional gel in order to make a gel cushion having voids therein.

This application is a division of application Ser. No. 08/652,714, filedMay 30, 1996.

The present invention generally relates to a method of making gelcushions, and more particularly relates to both a method of makingseamless, vacuum-molded, wrist support gel cushions, and gel cushionsmanufactured by such a method.

A recent surge in the number of wrist and arm occupational injuries,resulting from repetitive computer keyboard use, has prompted thedevelopment of countless devices directed at alleviating this modernproblem. "Carpal Tunnel Syndrome" has become a well known termdescribing a group of symptoms, including tendinitis, and epicondylitis,that occurs as a result of repetitive flexion of the wrist joints. Notonly are the symptoms of Carpal Tunnel Syndrome extremely painful, theyhave the potential to be permanently debilitating. Fortunately, it hasbeen found that if the causes of the disease are minimized or eliminatedin time, further damage therefrom may be averted.

Wrist wraps, directed at immobilizing the wrist joint, and wristsupports, directed at propping the hand at a position which minimizesrepetitive wrist flexion, have been heretofore developed. These devicesare used extensively by data entry personnel and other keyboardoperators in order to prevent wrist and arm injuries.

The present invention is directed at an inexpensive method formanufacturing gel cushions that may be used as highly effective,comfortable wrist supports. In a broad sense, the method may be used toproduce gel cushions for other uses.

Some prior art wrist supports, though designed to minimize repetitivewrist flexion, tend to be uncomfortable to use after a period of time.Notably, because such devices are typically positioned for supportingthe underside of a user's wrist, flow of-blood may be impeded by the useof rigid, non-yielding material.

Thus, a number of prior art wrist supports are comprised of softer, morecomfortable materials, such as foam rubber. Unfortunately, theresiliency of foam rubber, and other similar cellular materials, tendsto diminish after extended periods of use. Furthermore, foam rubbertends to wear unevenly, resulting in hardened areas where compression ismost regularly applied. Thus, foam rubber supports become lesscomfortable with time, necessitating frequent replacement thereof.

Cushioning devices having liquid or gel filled bladders have beendeveloped in the attempt to provide a more comfortable, more durablesupport for the wrist than is possible with solid or foam rubbersupports. For example, U.S. Pat. No. 5,435,508 discloses a wrist restsupport comprising a viscous, fluid-filled bladder removably inserted ina machine washable outer covering.

This prior art device, and others which are similar thereto, aremanufactured by several independent steps, including sewing or othermeans of assembling the bladder, filling the bladder with the desiredliquid, sealing the bladder such that it will resist leakage, andfashioning an outer covering in which to enclose the liquid filledbladder.

The present invention provides a substantially less complicated processfor manufacturing a comfortable fabric covered cushion that includes allthe advantages of a liquid support medium. Although the method of thepresent invention produces a fabric covered gel-cushion, no sewing,filling, sealing or gluing is required in the process of making thecushion.

Notably, because a gel cushion manufactured in accordance with thepresent invention does not include a fluid filled bladder, there is nopossibility that jewelry worn by the operator will rupture the cushionand cause leakage of its contents.

Furthermore, a gel cushion in accordance with the present invention isseamless due to the unique method of manufacturing same, thuseliminating the possibility of the cushion snagging delicate fabricsthat may be worn by the keyboard operator.

A gel cushion made in accordance with the method of the presentinvention will adhere to any typical surface on which it is placed, forexample, a desktop. This eliminates potential frustration suffered by akeyboard operator who must contend with a wrist support that migratesand slips along the desktop due to the natural movement of theoperator's hand and arm. Notably, the gel cushion requires no additionalcomponents to affix, clamp or secure the cushion to a surface. Thecushion may be quickly and easily removed, and its position readjustedas desired, when being used by more than one user.

Alternatively, the gel cushion may be used in combination with a supporttray, or the like. This is particularly useful when the gel cushion isused in conjunction with a mouse pad. In particular, the gel cushion maybe disposed in a tray which includes a conventional computer mouse pad,such that during operator control of a computer mouse, the wrist supportremains fixed in a spaced apart relationship with the mouse pad.

Overall, the present invention provides an inexpensive method ofmanufacturing a comfortable, durable gel cushion.

SUMMARY OF THE INVENTION

A method for manufacturing a gel cushion, in accordance with the presentinvention, generally comprises the steps of cooling a mold to a selectedtemperature; disposing a stretchable, porous fabric over the cooledmold; depositing a volume of gelable liquid into the mold onto anexposed side of the porous fabric, the gelable liquid entering pores ofthe fabric and the cooled mold preventing penetration of the porousfabric by causing the liquid to gelate in the pores; applying a vacuumbetween the fabric and the mold; allowing the remainder of the volume ofgel to gelate in the mold; and removing the gel cushion, having thefabric fixed thereto, from the mold.

The gelable liquid is preferably a thermoelastic compound which has lowfluid viscosity at elevated temperatures.

The method described herein is an improvement over the method describedin my copending patent application, entitled "Gel Cushion and Method ofManufacture", Ser. No. 08/652,692, filed on even date herewith, whichrequires the additional step of first coating the porous stretchablefabric with gel in order to enable vacuum forming thereof.

Importantly, the step of cooling the mold prior to disposing liquifiedgel onto the fabric disposed in the mold renders the fabric resistant tothe passage of both air and gel therethrough, which enables the vacuumforming of the fabric and produces a gel cushion having a clean fabriccovering.

More particularly, when said gelable liquid is poured or injected ontoan exposed side of the fabric, the liquid rapidly enters pores of thefabric, due to the applied vacuum which naturally stretches apart fabricfibers and pulls air and liquid therebetween. However, the cooled moldprevents the vacuum from pulling the liquid through the pores of thefabric by causing rapid gelation and freezing off of the liquid withinthe pores. Consequently, the fabric covering of the final product is notstained by gel, but instead has an attractive, clean appearance, and isnot tacky or sticky to the touch.

The cooling of the mold may be accomplished in any suitable manner.Preferably, however, the cooling includes the step of passing a coldliquid through channels or bores in the mold, and circulating the liquidsuch that the temperature of the mold remains substantially constant.Preferably, the selected temperature of the mold is between about 40degrees Fahrenheit and about 50 degrees Fahrenheit. However, this mayvary depending upon the temperature and composition of the gelableliquid utilized. The cold liquid may comprise, simply, cool water havinga temperature of about the selected temperature.

Preferably, the step of applying the vacuum is performed before andduring the step of depositing the gelable liquid. By applying the vacuumto the porous fabric before depositing the gelable liquid, the final gelcushion will maintain various surface contours, such as corners, or thelike.

The vacuum naturally stretches apart fabric fibers and enlarges thepores, or the interstices between said fibers. The pores will havevarying expansion over curved portions of the mold, and more uniformexpansion over flat portions of the mold.

During the depositing step, the enlarged pores become filled withgelable liquid which rapidly solidifies, or gelates, within the expandedpores. Upon removal of the gel cushion from the mold, the surfacecontours are maintained and supported by the gel in the expanded pores.

A remainder of the gelable liquid is allowed to gelate during thecooling and vacuuming steps. Finally, the gel, having the fabric fixedthereto, is removed from the mold. Because liquid gel has not penetratedthe fabric and contaminated surfaces of the mold, the mold may beimmediately used for the subsequent manufacturing of another gelcushion.

The gel cushion may now be used as a wrist rest or other cushion devicehaving a fabric upper surface and an adhesive lower surface comprised ofexposed, tacky gel. The adhesive surface enables the gel cushion to beremovably attached to a desk or other work surface, and easily peeledtherefrom if repositioning is desired.

Another embodiment of the present invention includes, in addition to thesteps hereinabove described, a neoprene backing may be applied to theexposed tacky gel and thereafter the gel cushion may be disposed in arigid support, for example a plastic tray.

The tray provides means for supporting the gel cushion in a rigidfashion and facilitates rapid repositioning thereof. In other words, thegel cushion of this embodiment may be repositioned on a desk or othersurface by simply moving the tray, rather than peeling the gel cushionas described above. In this regard, the rigid tray may be adjustable forcustomized height and tilt positioning of the wrist support.

Yet another embodiment of the present invention further comprises thesteps of utilizing a second mold, disposing stretchable, porous fabrictherein, depositing a second volume of gelable liquid, and vacuumforming as described above. In addition, the method includes the step ofpressing both gel-filled molds together while the volumes of warm liquidare allowed to gelate. Thus, the volumes of liquid become bondedtogether, producing a unitary gel structure enclosed in stretchablefabric.

The method of the present invention may include the step of removingextraneous portions of gel along edges of the filled mold, in order toproduce a smooth, attractive gel cushion, by pressing a mat against thefilled mold in order to sever extraneous gel from the gel cushion.

In addition, the gel cushion may be produced with air pockets, or voids,within the solidified gel in order to increase softness of the cushionas well as enable the cushion to adhere to angled surfaces.Particularly, air filled balloons, or hollow bags, made of gel or otherflexible material may be placed in the mold prior to the depositing ofthe gelable liquid in the mold such that the completed gel cushion willinclude air pockets formed by the balloons.

Although the present invention is well suited for producing gel cushionsto be used as comfortable wrist supports, it should be appreciated thatthe invention may be utilized to produce other cushion forms as well.Furthermore, the present invention encompasses a gel cushion made inaccordance with the methods briefly described hereinabove.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention may be more clearly understood with reference tothe following detailed description, in conjunction with the appendeddrawings of which:

FIG. 1 shows apparatus suitable for practicing a method formanufacturing a gel cushion in accordance with the present invention;

FIG. 2 shows a cross sectional view of the apparatus shown in FIG. 1;

FIG. 3 shows the gel cushion in accordance with the present invention,manufactured using the apparatus of FIG. 1, functioning as a wristsupport for an ergonomic keyboard;

FIGS. 4 and 5 show two additional types of wrist support gel cushionsproduced by the method of the present invention, each of these includinga rigid support tray;

FIG. 6 shows a cross sectional view of the wrist support gel cushiontaken along line 6--6 of FIG. 4.

FIG. 7 shows another embodiment of the present invention, particularly afabric enclosed gel cushion;

FIG. 8 shows apparatus suitable for manufacturing the fabric enclosedgel cushion shown in FIG. 7;

FIG. 9 shows a cross-sectional view of the fabric enclosed gel cushionshown in FIG. 7; and

FIG. 10 shows a cross sectional view of a gel cushion having a voidtherein for enabling bending of the gel cushion about an angled surface.

DETAILED DESCRIPTION

Turning now to FIGS. 1 and 2, an apparatus 10 suitable for manufacturinga gel cushion 12 in accordance with the method of the present inventionis shown.

The method generally comprises the steps of cooling a mold 14 to aselected temperature; disposing a stretchable, porous fabric 16 over thecooled mold 14; depositing a volume of gelable liquid 18 into the mold14 onto an exposed side 20 of the porous fabric 16, said gelable liquidentering pores 26 of the porous fabric 16 and said cooled mold 14preventing penetration of the gelable liquid 18 through the fabric 16 bycausing gelation of the gelable liquid 18 within said pores 26; applyinga vacuum (represented by arrow 28) between the fabric 16 and the mold 14in order to cause the fabric 16 to be stretched and vacuum formed;allowing a remainder 30 of the volume of gelable liquid 18 to gelate inthe mold 14; and removing the gel 18 and the vacuum formed fabric 16fixed thereto from the mold 14 in order to obtain a gel cushion 12.

It should be appreciated that the present invention also includes a gelcushion 12 made in accordance with the method described in detailherein.

The cooling of the mold 14 may be accomplished in any suitable manner.Preferably, in order to maintain substantially constant the selectedtemperature of the mold, the cooling may include the step of passing acool liquid, for example water, through bores 36 in the mold 14. Thecooling liquid may for example have a circulating flow path (representedby arrows 40).

The porous fabric 16 may be, for example, a two or four way stretchfabric, made of an elastomeric thread, preferably a segmentedpolyester-polyurethane, like that sold under the trade name "Lycra®",available from I.E. Dupont de Nemours and Company. It should beappreciated that many other types of porous, stretchable materials,including porous films, may be used in the method of the presentinvention.

As will be discussed in detail hereinafter, the method of the presentinvention enables the use of bare, stretchable fabrics 16 that includeno coating or lamination thereon. Thus, the gel cushion 12 will have acomforting, fluid feel to the user, as the soft gel 18 is nearly indirect contact with the user's touch.

The gelable liquid 18 preferably comprises a soft, easily moldedcomposition. More particularly, the gelable liquid may comprise athermoplastic compound having low fluid viscosity at elevatedtemperatures that can be pored or injection molded, and thereaftercooled to produce a rubbery, elastic gel having a high surface friction,for example a suitable thermoplastic elastomer.

Preferably, the mold is cooled to a selected temperature of betweenabout 40° F. and about 50° F., or less. Molding processing temperatureof the gelable liquid 18 will depend upon the particular thermoplasticcomposition being used, but preferably within the range of about 300° F.to about 500° F., or more.

It has been found that when the mold temperature is maintained withinsaid selected temperature range, rapid gelation occurs in the pores 26of the fabric 16, thereby preventing penetration of the fabric by theremaining gelable liquid 30. In other words, the chilled mold 14 acts tofreeze the hot liquid 18 at a point of which the liquid enters the pores26 and adheres to the fabric 16, but not at a point of enablingpenetration therethrough. The balance, or remaining portion 30, of thehot gelable liquid 18 will remain in a low viscosity state for a periodsufficient to flow through and completely fill the mold 14.

At this point, the fabric 16 is no longer porous, and consequently, isvacuum moldable. Importantly, the fabric 16 retains stretchability, asthe gel 18 within the pores 26 is highly elastic.

The mold 14, which includes selected contours 40 depending upon thedesired shape of the final gel cushion 12, may be adapted for vacuumforming in any suitable, conventional manner. For example, the mold 14may include vacuum ports 42 in communication with a hollowed cavity 44in the mold 14 to which a vacuum may be applied. The vacuum moldingenables smooth, intimate contact between the fabric 16 and the mold 14,producing an attractive, seamless fabric covered gel cushion 12.

The fabric 16 may be deposited in the mold 14 in any suitable manner.Preferably, however, the fabric 16 is placed within the mold 14, withedges of the fabric 16 suitably fastened thereto, in order to secureplacement of the fabric 16 during the vacuuming step.

While the vacuum is being applied, and before gelable liquid isdeposited in the mold 14, air will be forced through the fabric pores26, i.e. the spaces between fibers (not shown) of the fabric 16. Somestretching of the fabric 16 may occur at this point, thus widening thepores 26. Thus, when the gelable liquid 18 is deposited on the vacuumedfabric, it will naturally flow into the enlarged pores 26, facilitatedby suction from the vacuum.

Preferably, the step of applying the vacuum is performed before andduring the step of depositing the gelable liquid 18. By applying thevacuum to the porous fabric 16 before depositing the gelable liquid 18,the final gel cushion 12 will maintain the various surface contours 40,such as corners 46, or the like.

The vacuum naturally stretches the fabric and enlarges the pores 26, orthe interstices between said fibers. The pores 26 will have varyingdegrees of expansion over curved portions of the mold. For example,along concavely curved portions, such as the corners 46, the expansionof the pores 26 will tend to be increasing and larger than over flatportions 48 of the mold 14. This varying pore expansion over the contour40 of the mold is shown in cross section in FIG. 2.

During the depositing step, the enlarged pores 26 become filled withgelable liquid 18 which rapidly solidifies, or gelates, within theenlarged pores 26. Upon removal of the gel cushion 12 from the mold 14,the surface contour 40 is maintained and supported by the gel 18 in theenlarged pores 26.

The opening, or expansion of the pores 26 due to the vacuuming enablesgreater fluid flow of liquified gel thereinto. Importantly, such poreexpansion therefor provides for greater and more rapid cooling of thegel 18 in the pores 26 that are most expanded, due to closer proximityof the liquified gel 18 to the cooled mold 14, thus preventing fabricpenetration even in areas where pores 26 are most expanded.

In this respect, the present invention also includes a gel cushion 12comprising the stretchable fabric 16 with the selected contour 40, saidstretchable fabric 16 having expanded pores 26 of varying expansion overcurved portions of the stretchable fabric 16, and solidified gel 18which provides means for supporting the fabric 16 in the selectedcontour 40 and for maintaining the varying expansion of the pores 26.

Normally, any liquid, including gelable liquid, so deposited on a porousfabric having a vacuum applied thereto, will quickly penetrate thefabric. Moreover, the liquid may enter the vacuum ports, cause cloggingthereof and potentially, disable the vacuum system.

Importantly, the method of the present invention enables the liquid 18to be pulled into the fabric pores 26 while preventing penetrationtherethrough. Without the step of cooling of the mold to the selectedtemperature, the benefits of utilizing a high temperature, lowviscosity, liquified gel would not be realized (e.g. complete filling ofthe mold), as the final product 12 would be stained with tacky gel thathad been forced through the fabric 16 while in its liquid state.

Notably, the gelable liquid tends to temporarily soften and relax thefabric 16 upon contact therewith, facilitating the vacuum moldingthereof. Heat from the initial contact of the liquid 18 with the fabric16 causes the fabric 16 to be heat formed. Thus, for example, even heavygauge, porous fabrics may be used in the method of the presentinvention, as well as molds having substantial curvature. For themanufacturing of gel cushions 12 having increased comfort and softnesshowever, thin stretchable fabrics may be preferred in order to provide amore direct gel feel to the user.

While the vacuum is being applied, the gelable liquid 18 is allowed togelate in the mold 14. This step may be hastened by allowing the coolliquid to continue to pass through the mold 14 for a suitable timeperiod after the gelable liquid 18 has been deposited. Circulation ofthe cool liquid aids in uniform heat removal and consequently preventssink formations and other undesirable conditions in the finishedproduct.

The step of removing, i.e. extruding, the fabric covered gel cushion 12from the mold 14 may be accomplished in any suitable manner, forexample, by pressing a mat 50 (shown in FIG. 2) against the tacky gelsurface 52, lifting the mat 50 and peeling the cushion 12 therefrom. Thegel 18 provides means for supporting the stretchable fabric in theselected contour 40 of the mold 14.

Effectively, the fabric 16 has been heat formed by the initial contactwith the hot liquid 18 during the depositing step, and the shaperetained by subsequent gelation of the liquid 18 within the fabric pores26. This heat forming of the fabric 16 relieves the tendency of thefabric 16 to return to its original flat condition once removed from themold 14.

Notably, because the gelable liquid 18 does not penetrate or seepthrough the fabric 16 during the molding process, the mold 14 and vacuumports 42 are not contaminated by gel after the removal step, andconsequently, the mold 14 may be immediately reused for manufacturing ofanother gel cushion.

Referring now to FIG. 3, the gel cushion 12 produced by the hereinabovedescribed method, is shown as being used as a wrist rest for an operator(not shown) of an ergonomic computer keyboard 58. The cushion 12includes the smooth fabric covering 16 and removably adheres to asurface 60, such as a desktop, by means of the tacky gel surface 52 (onan underside of the cushion, so not shown in FIG. 3). As shown, thecushion 12 may adhered to the desktop 60 in a flexed position in orderto conform to contours of the keyboard 58.

Another embodiment 70 of the present invention is shown in FIGS. 4, 5,and 6. In particular, the gel cushion 70 may include a tray 72 forsupporting the gel cushion in a rigid fashion in order to facilitatepositioning thereof. Preferably, in order to facilitate positioning inthe tray 72 during the manufacturing of a gel cushion 70 in accordancewith this embodiment, a flexible material 74, such as neoprene, isaffixed to the tacky gel surface 52. The flexible material 74 may beaffixed during the step of allowing the gelable liquid 18 to cool andgelate.

The gel cushion 70 of this embodiment may be slidably repositioned, andthus may be preferred by some keyboard operators. Furthermore, withproper components added thereto, as known in the art, the rigid tray 72may be tilt and height adjustable for customization to a particularuser.

Alternatively, as shown in FIG. 5, a tray 76 may be configured toinclude a mouse pad 80 therein. Thus, the gel cushion 70 functions as awrist rest during use of a computer mouse 82, and maintains acomfortable alignment and position of an operator's wrist (not shown)with respect to the mouse pad 80.

FIGS. 7 shows yet another embodiment of the present invention,particularly, a fabric enclosed gel exercise cushion 90. In thisembodiment, two matching molds, in other words, a first and a secondmold, are used. An example of only the first 92 of two matching molds isshown in FIG. 8.

This embodiment comprises the steps described hereinabove with regard tothe fabric covered gel cushion 12 having a tacky lower gel surface (suchas shown in FIG. 3). However, this embodiment includes the use of thetwo matching molds 92, rather than a single mold. Generally, afterfilling of both matching molds, the two gel cushions are bonded togetherto produce the fabric enclosed gel cushion 90, having a cross section asshown in FIG. 9.

More particularly, a method for manufacturing the fabric enclosed gelcushion 90 comprises the steps of cooling the first and second molds 92to the selected temperature; disposing first and second stretchable,porous fabrics 94, 96 over the cooled molds 92; depositing a firstvolume 98 and a second volume 100 of gelable liquid into the molds 92onto exposed sides 102, 104 of the porous fabrics 94, 96; applying avacuum between the fabrics 94, 96 and the molds 92 in order to cause thefabrics 94, 96 to be stretched and vacuum formed; allowing a remainderof the volumes 98, 100 of gelable liquid to gelate; and bonding togetherthe volumes of gelable liquid 98, 100 by causing contact therebetweenduring the step of allowing the first volume 98 (and/or the secondvolume 100) to gelate.

The bonding step may include the step of simply pressing the first mold92 and second mold together in order to cause contact between exposedliquid gel surfaces 106, 108.

In order to ensure precise matching of the molds during the bondingstep, nubs 106, or the like, may be provided on the first mold 92 forbeing received by properly positioned indents on the second mold (notshown).

Finally, the fabric enclosed gel cushion 90 is removed from the matchingmolds 92. As shown in FIG. 7, the fabric enclosed gel cushion 90 may beused as a exercising device, by manual squeezing thereof. The fabriccovering 94, 96 is comfortable to the touch and the gel interior 98, 100provides sufficient resistance for exercising the muscles of hand andarm 109.

Another feature of the present invention is shown in FIG. 10. Inparticular, a gel cushion 110, in accordance with this embodiment of thepresent invention, may include one or more voids 112, or air pockets,therein for enabling bending or flexing of the cushion 110 about anangled surface 114.

In the method of the present invention, a gel cushion 110 having one ormore voids 112 therein includes, in addition to the steps describedabove regarding the embodiment shown in FIGS. 3-5, the step ofpositioning on the fabric 16 one or more hollow balloons, or bags 116,made of a flexible material, said positioning being performed before thestep of allowing the gelable liquid to gelate in the mold (not shown inFIG. 10).

More particularly, the hollow bag 116 may be positioned in a desiredmanner upon fabric 16 before or during the step of depositing thegelable liquid 18, such that the hollow bag 116 becomes substantiallysurrounded by gelable liquid 18. The gelable liquid 18 is then allowedto cool and gelate as described above.

The hollow bag 116 is preferably comprised of a material capable ofbonding with the gelable liquid 18. More particularly, the hollow bag116 may be comprised of a gel of the same composition as the gelableliquid 18. In this case, preferably walls 118 of the bag 116 aresufficiently thick to resist perforation by melting upon contact withthe hot gelable liquid 18. Air trapped inside the hollow bag 116 willtemporarily expand due to the heat contained in the gelable liquid 18surrounding the bag 116, but the resilience and elasticity of the bagwalls 118 enable substantial expansion without bursting thereof.

As shown in FIG. 10, the void 112 provides means for enabling the gelcushion 110 to be flexed, or bent, sharply around the angled surface114, while maintaining an ability of the gel cushion 110 to adherethereto. For example, the gel cushion 110 may be used as a safetybumper, or guard, on a corner of table, desk, computer, or the like.Without the void 112 therein, the gel cushion may tend to detach fromthe angled surface 114 due to the rubberiness of the gel 18.

The voids 112 formed in the gel cushion 110, by the hereinabovedescribed method, also tend to enhance softness of the cushion 110, andthus may increase comfort of some persons using the cushion 110.

In this respect, it should be appreciated that such voids may be anadded feature to the fabric enclosed gel cushion embodiment 90 describedhereinabove and shown in FIGS. 7-9. Thus, hand exercising devices may bemanufactured which offer different levels of resistance depending onvolume or number of voids therein.

Although there has been hereinabove described a gel cushion and a methodof manufacturing same, in accordance with the present invention, for thepurposes of illustrating the manner in which the invention may be usedto advantage, it will be appreciated that the invention is not limitedthereto. Accordingly, any and all modifications, variations, orequivalent arrangements which may occur to those skilled in the artshould be considered to be within the scope of the invention as definedin the appended claims.

What is claimed is:
 1. A gel cushion comprising:a stretchable fabrichaving a selected contour; and gel means for supporting the stretchablefabric in the selected contour, said gel means produced by: cooling amold having the selected contour to a selected temperature, disposingthe stretchable fabric over the cooled mold, depositing a volume ofgelable liquid into the mold onto an exposed side of the stretchablefabric, said gelable liquid entering pores of the stretchable fabric andsaid cooled mold preventing penetration of the gelable liquid throughthe fabric by causing gelation of the gelable liquid within the pores,applying a vacuum between the fabric and the mold in order to cause thefabric to be stretched and vacuum formed, the application of vacuumbeing performed during the step of depositing the volume of gelableliquid in order to maintain a surface contour of the gel cushion bycausing expansion of the pores and filling of the exposed pores with thegelable liquid; allowing a remainder of the volume of gelable liquid togelate in the mold, and removing the gel and the vacuum formed fabricfixed thereto from the mold.
 2. The gel cushion according to claim 1further comprising tray means for supporting the gel cushion in a rigidfashion.
 3. The gel cushion according to claim 1 wherein the gel meansdoes not penetrate the fabric.
 4. A gel cushion comprising:a stretchablefabric having a selected contour, said stretchable fabric havingexpanded pores of varying expansion over curved portions of thestretchable fabric; and gel means for supporting the fabric in theselected contour and for maintaining the varying expansion of the pores,said gel means produced by: depositing a volume of gelable liquid ontoan exposed side of the fabric, said gelable liquid entering the pores ofthe fabric; preventing penetration of the gelable liquid through thefabric by cooling the mold in order to cause gelation of the gelableliquid within said pores; applying a vacuum between the fabric and themold in order to cause the fabric to be stretched and vacuum formed, theapplication of vacuum being performed during the step of depositing thevolume of gelable liquid in order to maintain a surface contour of thegel cushion by causing expansion of the pores and filling of the exposedpores with the gelable liquid; allowing a remainder of the volume ofgelable liquid to gelate in the mold; and removing the gel and thevacuum formed fabric fixed thereto form the mold in order to obtain agel cushion.
 5. The gel cushion according to claim 4 wherein the gelmeans does not penetrate the fabric.
 6. The gel cushion according toclaim 4 further comprising tray means for supporting the gel cushion ina rigid fashion.
 7. A gel cushion exercising device comprising:a firstporous stretchable fabric; a second porous stretchable fabric; and gelmeans, enclosed by the stretchable fabrics, said gel means produced by:cooling a first mold and a second mold to a selected temperature,disposing the first stretchable fabric and the second stretchable fabricover the first cooled mold and the second cooled mold respectively,depositing a first volume of gelable liquid and a second volume of thegelable liquid into the molds onto exposed sides of the first and secondstretchable fabrics respectively, said gelable liquid entering pores ofthe stretchable fabrics and said cooled molds preventing penetration ofthe gelable liquid through the fabrics by causing gelation of thegelable liquid within said pores, applying a vacuum between thestretchable fabrics and the molds in order to cause the fabrics to bestretched and vacuum formed, the application of vacuum being performedduring the step of depositing the volume of gelable liquid in order tomaintain a surface contour of the gel cushion by causing expansion ofthe pores and filling of the expanded pores with the gelable liquid;allowing a remainder of the volumes of gelable liquid to gelate in themolds, bonding the volumes of gelable liquid together by causing contacttherebetween during the step of allowing the remainder of the volumes togelate, and removing the gel, having the fabrics enclosing and fixedthereto, from the molds.
 8. The gel cushion exercising device accordingto claim 7 wherein the selected temperature of the cooled mold isbetween about 40° F. and 50° F.
 9. The gel cushion exercising deviceaccording to claim 8 wherein the gelable liquid is deposited at atemperature of between about 300° F. and about 500° F.
 10. The gelcushion according to claim 7 wherein the gel means does not penetratethe fabric.
 11. The gel cushion according to claim 7 further comprisingtray means for supporting the gel cushion in a rigid fashion.